Machine and Method for Applying a Tread to a Tyre Carcass

ABSTRACT

A machine ( 1 ) and method for applying a tread ( 2 ) to a carcass ( 3 ) of a tire ( 4 ); the machine ( 1 ) has a rotary drum ( 5 ) supporting the carcass ( 3 ), a feed conveyor ( 6 ) for feeding the tread ( 2 ) to the rotary drum ( 5 ), a pressure roller ( 7 ) contacting the tread ( 2 ), an actuating device ( 8 ) for pushing the pressure roller ( 7 ) against the tread ( 2 ) with a force (F) of adjustable intensity, and a control unit ( 9 ) for regulating the intensity of the force (F) as a function of an error variable (E) calculated as the difference between the length (RCC) of the remaining portion of the circumference of the carcass ( 3 ), and the length (RTL) of the remaining portion of the tread ( 2 ); and the control unit ( 9 ) regulates the intensity of the force (F) by means of a proportional control block ( 12 ) having a gain (Kp) varying as a function of the value of the error variable (E) and as a function of the rate of change of the error variable (E).

TECHNICAL FIELD

The present invention relates to a machine and method for applying atread to a tyre carcass.

BACKGROUND ART

A machine for applying a tread to a tyre carcass, e.g. of the typedescribed in Patent Application EP-1230235-A2, comprises a rotary drumsupporting the carcass; a feed conveyor for feeding the tread to therotary drum; a pressure roller contacting the tread between the drum andthe feed conveyor; an actuating device for pushing the pressure rolleragainst the tread with a force of adjustable intensity; and a controlunit for regulating the intensity of the force produced by the actuatingdevice as a function of an error variable calculated as the differencebetween the length of the remaining portion of the circumference of thecarcass, and the length of the remaining portion of the tread. Otherexamples of machines for applying a tread to a tyre carcass aredescribed in Patents DE-2105765-A, U.S. Pat. No. 3,728,181-A1, U.S. Pat.No. 5,427,636-A1 and EP-0704296-A1.

The purpose of the pressure roller is to exert pulling force on, topermanently stretch, the tread; and a precise amount of permanentstretch must be produced on the tread to achieve the desiredpredetermined overlap of the two free ends of the tread when it is woundabout the carcass.

When applying a cured new tread to a carcass as part of a tyreretreading process involving no curing, the new tread must be cut takinginto account the tread pattern, and so cannot be cut exactly to sizewith respect to the actual circumference of the carcass. Thetread-stretching action of the pressure roller is therefore essential inensuring correct application of the tread to the carcass. When applyinga green tread to a carcass as part of the original tyre manufacturingprocess or as part of a tyre retreading and curing process, the newtread is cut exactly to size with respect to the actual circumference ofthe carcass, but may subsequently undergo a slight, unpredictablevariation in length due to shrinkage caused by changes in temperature.In which case, the tread-stretching action of the pressure roller mayprove useful in ensuring correct application of the tread to thecarcass.

The control unit of known machines for applying a tread to a tyrecarcass, e.g. of the type marketed by SH under the trade name “HitechExtru-Builder Baz 2160”, comprises a PID(Proportional-Derivative-Integral) control block, which regulates theintensity of the force produced by the actuating device as a function ofthe error variable.

Numerous tests show precise tread stretch by the pressure roller ofknown machines for applying a tread to a tyre carcass to be extremelydifficult to achieve. To increase tread stretch precision of thepressure roller, it has been proposed to increase gain of the integralcontribution, which, however, results in oscillating and potentiallyunstable control, with obvious anomalous stress of the tread. To reduceoscillation, therefore, it has been proposed to increase gain of thederivative contribution, which in turn reduces control speed andprevents sufficient error reduction in the time taken to apply thetread.

DISCLOSURE OF INVENTION

It is an object of the present invention to provide a machine and methodfor applying a tread to a tyre carcass, designed to eliminate theaforementioned drawbacks, and which, in particular, are cheap and easyto implement.

According to the present invention, there are provided a machine andmethod for applying a tread to a tyre carcass, as recited in theaccompanying Claims.

BRIEF DESCRIPTION OF THE DRAWINGS

A non-limiting embodiment of the present invention will be described byway of example with reference to the accompanying drawings, in which:

FIG. 1 shows a schematic view in perspective of a machine for applying atread to a tyre carcass in accordance with the present invention;

FIG. 2 shows a diagram of a control unit of the FIG. 1 machine;

FIG. 3 shows a graph of an error variable controlled by the FIG. 2control unit.

BEST MODE FOR CARRYING OUT THE INVENTION

Number 1 in FIG. 1 indicates as a whole a machine for applying a tread 2to a carcass 3 of a tyre 4. Machine 1 comprises a rotary drum 5supporting carcass 3; a feed conveyor 6 for feeding tread 2 to rotarydrum 5; a pressure roller 7 contacting tread 2 between drum 5 and feedconveyor 6; and an actuating device 8 (in particular, a pneumatic pistoncontrolled by a proportional solenoid valve) for pushing pressure roller7 against tread 2 with a force F of adjustable intensity.

A control unit 9 regulates the intensity of force F produced byactuating device 8 as a function of an error variable E calculated asthe difference between the length RCC of the remaining portion of thecircumference of carcass 3, and the length RTL of the remaining portionof tread 2. To do this, control unit 9 is connected to a sensor 10 formeasuring feed of tread 2, i.e. for measuring the value of length RTL ofthe remaining portion of tread 2; and to a sensor 11 for measuringrotation of carcass 3, i.e. for measuring length RCC of the remainingportion of the circumference of carcass 3.

The purpose of control unit 9 is to zero the value of error variable Eby the time tread 2 is applied to carcass 3. A constant quantity orso-called “Stretch Factor” may be added automatically to error variableE to achieve a given overlap of the two ends of tread 2.

As shown in FIG. 2, control unit 9 comprises a proportional controlblock 12 having a variable gain Kp, and which regulates the intensity offorce F produced by actuating device 8 as a function of error variableE. The value of gain Kp of proportional control block 12 is modifieddynamically by a computing block 13 as a function of the value of errorvariable E, and as a function of the rate of change, i.e. the firstderivative, of error variable E.

In a preferred embodiment, computing block 13 checks gain Kp ofproportional control block 12 with a given time frequency, and, for eachcheck, operates according to the following control strategy:

computing block 13 maintains gain Kp of proportional control block 12constant when the absolute value of error variable E is above athreshold EL, and when the rate of change of error variable E, inabsolute value, is above a threshold VL;

computing block 13 increases gain Kp of proportional control block 12when the absolute value of error variable E is above threshold EL, andwhen the rate of change of error variable E, in absolute value, is belowthreshold VL;

computing block 13 reduces gain Kp of proportional control block 12 whenthe absolute value of error variable E is below threshold EL, and whenthe rate of change of error variable E, in absolute value, is abovethreshold VL; and

computing block 13 maintains gain Kp of proportional control block 12constant when the absolute value of error variable E is below thresholdEL, and when the rate of change of error variable E, in absolute value,is below threshold VL.

Good test results have been obtained when computing block 13, ifnecessary, modifies gain Kp of proportional control block 12 at 2 Hzfrequency and by a given IGF quantity equal to 50% of the initial valueof gain Kp of proportional control block 12; and even better testresults, in terms of speed and precision, have been obtained when aconstant so-called “Fixed Pressure” quantity is added to the outputvalue of proportional control block 12.

Threshold EL preferably has a first value when error variable E ispositive, and a second value when error variable E is negative, i.e. theabsolute value of threshold EL differs, depending on whether errorvariable E is positive or negative. Typically, the absolute value ofthreshold EL is higher when error variable E is positive than when errorvariable E is negative.

In an alternative embodiment, computing block 13 only adjusts gain Kp ofproportional control block 12 as a function of the value of errorvariable E, without taking into account the rate of change of errorvariable E. More specifically, computing block 13 increases gain Kp ofproportional control block 12 when the absolute value of error variableE is above a threshold VS1; reduces gain Kp of proportional controlblock 12 when the absolute value of error variable E is below athreshold VS2; and maintains gain Kp of proportional control block 12constant when the absolute value of error variable E lies betweenthreshold VS1 and threshold VS2.

FIG. 3 shows the results of two tests, and more specifically a timegraph of error variable E relative to two different applications oftread 2.

The parameter values of control unit 9—i.e. the initial value of gain Kpof proportional control block 12, the update frequency of gain Kp ofproportional control block 12, and the IGF quantity by which gain Kp ofproportional control block 12 is varied—are determined experimentally,and normally depend on the construction characteristics of the controlunit. Optimum “Fixed Pressure” and “Stretch Factor” values must also bedetermined experimentally for different types of tread 2.

Machine 1 as described above may be used, with excellent results, forapplying a cured new tread to a carcass as part of a tyre retreadingprocess involving no curing, or for applying a green tread to a carcassas a part of the original tyre manufacturing process or as part of atyre retreading and curing process. Tests of both applications showmachine 1, as described above, ensures a highly precise and, above all,constant final value of error variable E.

1. A machine (1) for applying a tread (2) to a carcass (3) of a tyre(4); the machine (1) comprising: a rotary drum (5) supporting thecarcass (3); a feed conveyor (6) for feeding the tread (2) to the rotarydrum (5); a pressure roller (7) contacting the tread (2) between therotary drum (5) and the feed conveyor (6); an actuating device (8) forpushing the pressure roller (7) against the tread (2) with a force (F)of adjustable intensity; and a control unit (9) for regulating theintensity of the force (F) produced by the actuating device (8) as afunction of an error variable (E) calculated as the difference betweenthe length (RCC) of the remaining portion of the circumference of thecarcass (3), and the length (RTL) of the remaining portion of the tread(2); and the machine (1) being characterized in that the control unit(9) comprises a proportional control block (12) having a variable gain(Kp) and which regulates the intensity of the force (F) produced by theactuating device (8) as a function of the error variable (E); and acomputing block (13) which varies the gain (Kp) of the proportionalcontrol block (12) as a function of the value of the error variable (E).2. A machine (1) as claimed in claim 1, wherein the computing block (13)varies the gain (Kp) of the proportional control block (12) as afunction of the value of the error variable (E) and as a function of therate of change of the error variable (E).
 3. A machine (1) as claimed inclaim 2, wherein: the computing block (13) maintains the gain (Kp) ofthe proportional control block (12) constant when the value of the errorvariable (E) is above a first threshold (EL) in absolute value, and whenthe rate of change of the error variable (E) is above a second threshold(VL) in absolute value; the computing block (13) increases the gain (Kp)of the proportional control block (12) when the value of the errorvariable (E) is above the first threshold (EL) in absolute value, andwhen the rate of change of the error variable (E) is below the secondthreshold (VL) in absolute value; the computing block (13) reduces thegain (Kp) of the proportional control block (12) when the value of theerror variable (E) is below the first threshold (EL) in absolute value,and when the rate of change of the error variable (E) is above thesecond threshold (VL) in absolute value; the computing block (13)maintains the gain (Kp) of the proportional control block (12) constantwhen the value of the error variable (E) is below the first threshold(EL) in absolute value, and when the rate of change of the errorvariable (E) is below the second threshold (VL) I absolute value.
 4. Amachine (1) as claimed in claim 2, wherein the computing block (13)increases the gain (Kp) of the proportional control block (12) when thevalue of the error variable (E) is above a first threshold (EL) inabsolute value, and when the rate of change of the error variable (E) isbelow a second threshold (VL) in absolute value.
 5. A machine (1) asclaimed in claim 2, wherein the computing block (13) reduces the gain(Kp) of the proportional control block (12) when the value of the errorvariable (E) is below a first threshold (EL) in absolute value, and whenthe rate of change of the error variable (E) is above a second threshold(VL) in absolute value.
 6. A machine (1) as claimed in claim 3, whereinthe computing block (13) modifies the gain (Kp) of the proportionalcontrol block (12) with a frequency of 2 Hz and by a given quantity(IGF) equal to 50% of the initial value of the gain (Kp) of theproportional control block (12).
 7. A machine (1) as claimed in claim 3,wherein the first threshold (EL) has a first value when the errorvariable (E) is positive, and a second value when the error variable (E)is negative.
 8. A machine (1) as claimed in claim 7, wherein the firstvalue of the first threshold (EL) is higher than the second value of thefirst threshold (EL).
 9. A machine (1) as claimed in claim 1, whereinthe computing block (13) increases the gain (Kp) of the proportionalcontrol block (12) when the absolute value of the error variable (E) isabove a third threshold (VS1), reduces the gain (Kp) of the proportionalcontrol block (12) when the absolute value of the error variable (E) isbelow a fourth threshold (VS2), and maintains the gain (Kp) of theproportional control block (12) constant when the absolute value of theerror variable (E) lies between the third threshold (VS 1) and thefourth threshold (VS2).
 10. A machine as claimed in claim 1, wherein afirst constant quantity is added automatically to the error variable (E)to obtain a given overlap of the two ends of the tread (2).
 11. Amachine as claimed in claim 1, wherein a second constant quantity isadded to an output value of the proportional control block (12).
 12. Amethod of applying a tread (2) to a carcass (3) of a tyre (4); themethod comprising: mounting the carcass (3) onto a rotary drum (5);applying a first end of the tread (2) to the carcass (3); feeding thetread (2) to the carcass (3), while at the same time rotating the rotarydrum (5); applying a pressure force (F) on the tread (2) by means of apressure roller (7) contacting the tread (2) between the rotary drum (5)and a feed conveyor (6) for feeding the tread (2); calculating an errorvariable (E) as the difference between the length (RCC) of the remainingportion of the circumference of the carcass (3), and the length (RTL) ofthe remaining portion of the tread (2); and regulating the intensity ofthe force (F) applied by the pressure roller (7) as a function of theerror variable (E); the method being characterized by regulating theintensity of the force (F) applied by the pressure roller (7) by meansof a proportional control block (12) having a variable gain (Kp); and byvarying the gain (Kp) of the proportional control block (12) as afunction of the value of the error variable (E).
 13. A method as claimedin claim 12, wherein the gain (Kp) of the proportional control block(12) is varied as a function of the value of the error variable (E), andas a function of the rate of change of the error variable (E).
 14. Amethod as claimed in claim 13, wherein: the gain (Kp) of theproportional control block (12) is maintained constant when the value ofthe error variable (E) is above a first threshold (EL) in absolutevalue, and when the rate of change of the error variable (E) is above asecond threshold (VL) in absolute value; the gain (Kp) of theproportional control block (12) is increased when the value of the errorvariable (E) is above the first threshold (EL) in absolute value, andwhen the rate of change of the error variable (E) is below the secondthreshold (VL) in absolute value; the gain (Kp) of the proportionalcontrol block (12) is reduced when the value of the error variable (E)is below the first threshold (EL) in absolute value, and when the rateof change of the error variable (E) is above the second threshold (VL)in absolute value; the gain (Kp) of the proportional control block (12)is maintained constant when the value of the error variable (E) is belowthe first threshold (EL) in absolute value, and when the rate of changeof the error variable (E) is below the second threshold (VL) in absolutevalue.
 15. A method as claimed in claim 12, wherein a first constantquantity is added automatically to the error variable (E) to obtain agiven overlap of the two ends of the tread (2).
 16. A method as claimedin claim 12, wherein a second constant quantity is added to an outputvalue of the proportional control block (12).